strut attachment AD - failed

[N74DV]

Well... mine failed. Corrosion and a crack on the left side and corrosion on the right.

Depressing. Spent about $9,000 on an annual a few months ago and now being told it could cost me $5,000 to replace the fittings.

I think at this point I should bring the plane home and begin a restoration. The fabric is 36 years old.

So let's see.... I've got about $33,000 into this plane now and looks like another $8,000 if I recover and minor restoration? jeeeez... someone shoot me.

[Dano"T"]

Re: strut attachment AD - failed

That really sucks....but at least your wing didn't fall off and you didn't die. We're glad you'll be around a while. I still think the $9,000 annual is a CRIME. I'm very careful about who I bring my plane to. Sorry man.

[Howard Wilson]

Re: strut attachment AD - failed

$5K sounds awful steep!! What's the availability of the fittings? Any good aircraft welder should be able to do that with a minimal amount of fabric repair. Maybe $1000 tops, should be half of that. What am I missing. Is it the same IA that did your annual and missed this that's giving you the quote? Might depend on the extent of corrosion in surrounding tube??

[N74DV]

Re: strut attachment AD - failed

Not the same IA. I won't use that shop again. This is a different guy who comes recommended to me.

He based the cost estimate off the AD itself. I guess the AD says it will cost about $5K to replace the fittings.

I am glad this AD came out. It certainly saved my hide and whomever may have been flying with me!

[astjp2]

Re: strut attachment AD - failed

Just weld it, and do a 337 for a major repair, I would not replace.....I know of one that you can get if needed. Tim

[N96337]

Re: strut attachment AD - failed

Not the same IA. I won't use that shop again. This is a different guy who comes recommended to me.

He based the cost estimate off the AD itself. I guess the AD says it will cost about $5K to replace the fittings.

I am glad this AD came out. It certainly saved my hide and whomever may have been flying with me!

DJ, I'm so sorry to hear this! However.... I'd NOT go back to the IA that gave you that huge bill...but I'd for sure let him know that he missed this... and how bad and serious it is!!! He needs a bit of educating....let him sweat a bit...he deserves that! It's pretty basic to really take a close look at all strut attachment fittings...inside and out (for lack of a better term) and in fact, it's required as per FAR 43 Appendix D, paragraph f... I doubt that corrosion and the crack has formed in the short while that you've had the aircraft in the air since his annual inspection...he needs to learn to look at the IMPORTANT things as well as the rest of the stuff!!!!! (before he lets someone get hurt or killed!) All that said, I'm not seeing how it could cost $5000 to fix it...but with fabric that old, you may be right to pull it and take the plunge. I'm glad you found it before it became a real problem!
John

[N74DV]

Re: strut attachment AD - failed

Just weld it, and do a 337 for a major repair,

Really? is this an approved method of compliance? Sounds great if I can do this! More info please. How do I convince the A&P that I can go this route?

Also how does one go about cleaning out the corrosion? The A&P says it seems nearly impossible to get into the area to remove corrosion.

[VictorBravo]

Re: strut attachment AD - failed

DJ, we have one of the best and most respected aircraft certified welders in the country (Mike Jewett) within an hour West of Los Angeles. For $5000 you can put your fuselage on a trailer, drive it here to LA, paying $4.50 a gallon for gas, have him weld it back together or replace the fitting, stay in a motel for a couple of days, drive home, and have $2500-3000 change left in your pocket.

The fabric may be fine for another few years if it is Dacron, done correctly, and stored indoors. Do NOT assume you need a full restoration.

Bill

[Buell Powell]

Re: strut attachment AD - failed

DJ,
I can see how the crack might be caused if someone wasn't careful when installing the struts or they were hit while on the plane but I would really think about if the fittings are corroded then what else might be and do a close inspection. Hope the corrosion is just surface rust and hasn't pitted the metal and you can have the crack welded and the rest is in good shape.

[Carl E. Carson]

Re: strut attachment AD - failed

DJ: So sorry to hear about the strut attachment. For you other guys I flew with DJ last winter while spending 3 months in the Phoenix area. He is a really nice guy, loves everything about aviation AND is beeming with enthusiasm. Hopefully DJ, you can find the right connection to someone who will help you out of this without a great amount of money.

Best wishes,

Carl

[jdoran]

Re: strut attachment AD - failed

DJ,

I am a seaplane operating from brackish water.

Over the years, the bracket and surrounding areas had been painted, painted, painted, sprayed with goop, all in an effort to protect the area from corrosion. There was so much stuff, you really couldn't inspect the area to comply with the SB.

We cut away the fabric and sandblasted the area to bare metal using an inexpensive blaster hooked to a small shop (Sears) compressor. The sand gets into ALL the nooks and crannies.

I guess I'm glad the AD forced me and the A+P to really clean up and check this area out. We had the area x-rayed as well just for peace of mind.

This is an inexpensive way to clean your bracket area and have the welding repair done without spending a fortune to completely rebuild the plane.

[N74DV]

Re: strut attachment AD - failed

thanks for all the great info guys. You're giving me some excellent feedback. I'm going to the shop on Monday morning to meet with the A&P. I'm going to print out this thread and carry along with me.

With some luck I may be able to get flying again cheaper and sooner that I had thought.

One positive note was he tested the fabric again while he looked at the fittings. I still have Irish Linen on the plane so he used a Maule tester. Said the punch test passed no problem. So looks like I can still go another year or more before a recover.

[crispy critter]

Re: strut attachment AD - failed

thanks for all the great info guys. You're giving me some excellent feedback. I'm going to the shop on Monday morning to meet with the A&P. I'm going to print out this thread and carry along with me.

With some luck I may be able to get flying again cheaper and sooner that I had thought.

One positive note was he tested the fabric again while he looked at the fittings. I still have Irish Linen on the plane so he used a Maule tester. Said the punch test passed no problem. So looks like I can still go another year or more before a recover.

Do you know how hard he punched the fabric? The maule tester is a dull point tool that is like a spring slide,the harder you push the more pounds of pressure the tool reads. I just wonder after 30 years(I believe that's what you said)how much pressure he punched it up too. On ceconite airplanes(which is what the tester was made to test) 30-35lbs is normally what most flunk it at.....I can't imagine 30 year old cotton punching 30lbs and holding....nothing for you to worry about but I was just curious for my own wondering mind.

[Marv]

Re: strut attachment AD - failed

Keven i may be wrong, but i think you have it backwards. The maule tester was made for cotton and Irish linen, and there is no maule test for ceconite. Marv

[N74DV]

Re: strut attachment AD - failed

I think the Maule tester is for organic fiber covering isn't it?? He told me he tested up to 47lb and did not punch through.

The fabric was done in 1971 but it was kept in a garage for about 35 years. Only been outdoors for about 3 years.